Semiconductor device and method of manufacturing the same

ABSTRACT

A semiconductor device and a method of manufacturing the same are disclosed. The semiconductor device includes semiconductor wires disposed over a substrate, a source/drain epitaxial layer in contact with the semiconductor wires, a gate dielectric layer disposed on and wrapping around each channel region of the semiconductor wires, a gate electrode layer disposed on the gate dielectric layer and wrapping around the each channel region, and dielectric spacers disposed in recesses formed toward the source/drain epitaxial layer.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.16/512,326 filed on Jul. 15, 2019, which is a divisional of U.S. patentapplication Ser. No. 15/941,798 filed Mar. 30, 2018, now U.S. Pat. No.10,355,102, which claims priority to U.S. Provisional Patent Application62/586,709 filed on Nov. 15, 2017, the entire disclosure of each ofwhich applications are incorporated herein by reference.

TECHNICAL FIELD

The disclosure relates to methods of manufacturing semiconductorintegrated circuits, and more particularly to methods of manufacturingsemiconductor devices including fin field effect transistors (FinFETs)and/or gate-all-around (GAA) FETs, and semiconductor devices.

BACKGROUND

Traditional planar thin film devices provide superior performance withlow power consumption. To enhance the device controllability and reducethe substrate surface area occupied by the planar devices, thesemiconductor industry has progressed into nanometer technology processnodes in pursuit of higher device density, higher performance, and lowercosts. Challenges from both fabrication and design issues have resultedin the development of three-dimensional designs, such as a multi-gatefield effect transistor (FET), including a fin FET (Fin FET) and agate-all-around (GAA) FET. In a Fin FET, a gate electrode is adjacent tothree side surfaces of a channel region with a gate dielectric layerinterposed therebetween. Because the gate structure surrounds (wraps)the fin on three surfaces, the transistor essentially has three gatescontrolling the current through the fin or channel region.Unfortunately, the fourth side, the bottom part of the channel is faraway from the gate electrode and thus is not under close gate control.In contrast, in a GAA FET, all side surfaces of the channel region aresurrounded by the gate electrode, which allows for fuller depletion inthe channel region and results in less short-channel effects due tosteeper sub-threshold current swing (SS) and smaller drain inducedbarrier lowering (DIBL). As transistor dimensions are continually scaleddown to sub 10-15 nm technology nodes, further improvements of the GAAFET are required.

BRIEF DESCRIPTION OF THE DRAWINGS

The present disclosure is best understood from the following detaileddescription when read with the accompanying figures. It is emphasizedthat, in accordance with the standard practice in the industry, variousfeatures are not drawn to scale and are used for illustration purposesonly. In fact, the dimensions of the various features may be arbitrarilyincreased or reduced for clarity of discussion.

FIGS. 1A-1D show various views of a semiconductor FET device accordingto an embodiment of the present disclosure. FIG. 1A shows a crosssectional view along the X direction (source-to-drain direction), FIG.1B shows a cross sectional view along the Y1-Y1 direction of FIG. 1A,FIG. 1C shows a cross sectional view along the Y2-Y2 direction of FIG.1A, and FIG. 1D shows a cross sectional view along the Y3-Y3 directionof FIG. 1A.

FIGS. 2A-2D show various views of a semiconductor FET device accordingto another embodiment of the present disclosure. FIG. 2A shows a crosssectional view along the X direction (source-to-drain direction), FIG.2B shows a cross sectional view along the Y1-Y1 direction of FIG. 2A,FIG. 2C shows a cross sectional view along the Y2-Y2 direction of FIG.2A, and FIG. 2D shows a cross sectional view along the Y3-Y3 directionof FIG. 2A.

FIGS. 3A-3D show various views of a semiconductor FET device accordingto another embodiment of the present disclosure. FIG. 3A shows a crosssectional view along the X direction (source-to-drain direction), FIG.3B shows a cross sectional view along the Y1-Y1 direction of FIG. 3A,FIG. 3C shows a cross sectional view along the Y2-Y2 direction of FIG.3A, and FIG. 3D shows a cross sectional view along the Y3-Y3 directionof FIG. 3A.

FIGS. 4A-4D show various views of a semiconductor FET device accordingto another embodiment of the present disclosure. FIG. 4A shows a crosssectional view along the X direction (source-to-drain direction), FIG.4B shows a cross sectional view along the Y1-Y1 direction of FIG. 4A,FIG. 4C shows a cross sectional view along the Y2-Y2 direction of FIG.1A, and FIG. 4D shows a cross sectional view along the Y3-Y3 directionof FIG. 4A.

FIGS. 5A and 5B show one of the various operations of manufacturing asemiconductor GAA FET device according to an embodiment of the presentdisclosure.

FIGS. 6A and 6B show one of the various operations of manufacturing asemiconductor GAA FET device according to an embodiment of the presentdisclosure.

FIGS. 7A and 7B show one of the various operations of manufacturing asemiconductor GAA FET device according to an embodiment of the presentdisclosure. FIG. 7A shows a cross sectional view for an n-type GAA FET,and FIG. 7B shows a cross sectional view for a p-type GAA FET.

FIGS. 8A and 8B show one of the various operations of manufacturing asemiconductor GAA FET device according to an embodiment of the presentdisclosure. FIG. 8A shows a cross sectional view for an n-type GAA FET,and FIG. 8B shows a cross sectional view for a p-type GAA FET.

FIGS. 9A and 9B show one of the various operations of manufacturing asemiconductor GAA FET device according to an embodiment of the presentdisclosure. FIG. 9A shows a cross sectional view for an n-type GAA FET,and FIG. 9B shows a cross sectional view for a p-type GAA FET.

FIGS. 10A and 10B show one of the various operations of manufacturing asemiconductor GAA FET device according to an embodiment of the presentdisclosure. FIG. 10A shows a cross sectional view for an n-type GAA FET,and FIG. 10B shows a cross sectional view for a p-type GAA FET.

FIGS. 11A and 11B show one of the various operations of manufacturing asemiconductor GAA FET device according to an embodiment of the presentdisclosure. FIG. 11A shows a cross sectional view for an n-type GAA FET,and FIG. 11B shows a cross sectional view for a p-type GAA FET.

FIGS. 12A and 12B show one of the various operations of manufacturing asemiconductor GAA FET device according to an embodiment of the presentdisclosure. FIG. 12A shows a cross sectional view for an n-type GAA FET,and FIG. 12B shows a cross sectional view for a p-type GAA FET.

FIGS. 13A and 13B show one of the various operations of manufacturing asemiconductor GAA FET device according to an embodiment of the presentdisclosure. FIG. 13A shows a cross sectional view for an n-type GAA FET,and FIG. 13B shows a cross sectional view for a p-type GAA FET.

FIGS. 14A and 14B show one of the various operations of manufacturing asemiconductor GAA FET device according to an embodiment of the presentdisclosure. FIG. 14A shows a cross sectional view for an n-type GAA FET,and FIG. 14B shows a cross sectional view for a p-type GAA FET.

FIGS. 15A and 15B show one of the various operations of manufacturing asemiconductor GAA FET device according to an embodiment of the presentdisclosure. FIG. 15A shows a cross sectional view for an n-type GAA FET,and FIG. 15B shows a cross sectional view for a p-type GAA FET.

FIGS. 16A and 16B show one of the various operations of manufacturing asemiconductor GAA FET device according to an embodiment of the presentdisclosure. FIG. 16A shows a cross sectional view for an n-type GAA FET,and FIG. 16B shows a cross sectional view for a p-type GAA FET.

FIGS. 17A, 17B, 17C, 17D, and 17E show various inner spacers coated withgate dielectric layers, according to embodiments of the presentdisclosure.

DETAILED DESCRIPTION

It is to be understood that the following disclosure provides manydifferent embodiments, or examples, for implementing different featuresof the invention. Specific embodiments or examples of components andarrangements are described below to simplify the present disclosure.These are, of course, merely examples and are not intended to belimiting. For example, dimensions of elements are not limited to thedisclosed range or values, but may depend upon process conditions and/ordesired properties of the device. Moreover, the formation of a firstfeature over or on a second feature in the description that follows mayinclude embodiments in which the first and second features are formed indirect contact, and may also include embodiments in which additionalfeatures may be formed interposing the first and second features, suchthat the first and second features may not be in direct contact. Variousfeatures may be arbitrarily drawn in different scales for simplicity andclarity.

Further, spatially relative terms, such as “beneath,” “below,” “lower,”“above,” “upper” and the like, may be used herein for ease ofdescription to describe one element or feature's relationship to anotherelement(s) or feature(s) as illustrated in the figures. The spatiallyrelative terms are intended to encompass different orientations of thedevice in use or operation in addition to the orientation depicted inthe figures. The apparatus may be otherwise oriented (rotated 90 degreesor at other orientations) and the spatially relative descriptors usedherein may likewise be interpreted accordingly. In addition, the term“being made of” may mean either “comprising” or “consisting of.” In thepresent disclosure, a phrase “one of A, B and C” means “A, B and/or C”(A, B, C, A and B, A and C, B and C, or A, B and C), and does not meanone element from A, one element from B and one element from C, unlessotherwise described.

Generally, it is difficult to control lateral etching amounts when thenanowires (NWs) are released by selectively etching sacrificialsemiconductor layers. The lateral ends of the NWs may be etched when theNW release etching process is performed after a dummy poly gate isremoved, because a lateral etching control or an etching budget for NWrelease etching may not be sufficient. A gate electrode may touch asource/drain epitaxial layer if there is no etch stop layer. Further,there is a larger impact on gate-to-drain capacitance Cgd. If nodielectric film existed between the gate and the source/drain region,Cgd becomes larger, which would reduce circuit speed.

In a GAA FET, an inner spacer is provided between a metal gate electrodeand a source/drain epitaxial layer. However, it is difficult touniformly form inner spacers due to process variations not only in eachdevice but also within the overall wafer, and/or wafer-to-wafervariations. Further, it is necessary to provide better gate control fora GAA FET having inner spacers. The inner spacers act as an extraresource of channel resistance, thereby hindering the gate controlcapability. A higher channel height in a GAA FET causes moredifficulties in deposition and etching processes, to more preciselycontrol a uniformity of the structure from the channel bottom to thechannel top. In particular, achieving higher process uniformity within a12-inch wafer becomes more difficult in a GAA FET fabrication operation.

In the present disclosure, a novel method for fabricating an innerspacer between a metal gate electrode and a source/drain epitaxial layerfor a GAA FET and a stacked channel FET are provided. In particular, inthe present disclosure, the inner spacer has a cross sectional shapeformed in a recess (i.e. a portion of the inner spacer having a surfaceof an indented shape) provided in a region not overlapping the gateelectrode. In some embodiments, the recess is provided in thesource/drain regions. By employing the inner spacer, it is possible toprovide more space for a gate dielectric layer and a gate electrode,thereby improving the gate control capability.

In this disclosure, a source/drain refers to a source and/or a drain. Itis noted that in the present disclosure, a source and a drain areinterchangeably used and the structures thereof are substantially thesame.

FIGS. 1A-1D show various views of a semiconductor GAA FET deviceaccording to an embodiment of the present disclosure. FIG. 1A is a crosssectional view along the X direction (source-to-drain direction), FIG.1B is a cross sectional view along the Y1-Y1 direction of FIG. 1A, FIG.1C is a cross sectional view along the Y2-Y2 direction of FIG. 1A, andFIG. 1D shows a cross sectional view along the Y3-Y3 direction of FIG.1A.

As shown in FIGS. 1A-1C, semiconductor wires 25 are provided over asemiconductor substrate 10, and vertically arranged along the Zdirection (the normal direction of the principal surface of thesubstrate 10). In some embodiments, the substrate 10 includes a singlecrystalline semiconductor layer on at least it surface portion. Thesubstrate 10 may include a single crystalline semiconductor materialsuch as, but not limited to Si, Ge, SiGe, GaAs, InSb, GaP, GaSb, InAlAs,InGaAs, GaSbP, GaAsSb and InP. In certain embodiments, the substrate 10is made of crystalline Si.

The substrate 10 may include in its surface region, one or more bufferlayers (not shown). The buffer layers can serve to gradually change thelattice constant from that of the substrate to that of the source/drainregions. The buffer layers may be formed from epitaxially grown singlecrystalline semiconductor materials such as, but not limited to Si, Ge,GeSn, SiGe, GaAs, InSb, GaP, GaSb, InAlAs, InGaAs, GaSbP, GaAsSb, GaN,GaP, and InP. In a particular embodiment, the substrate 10 comprisessilicon germanium (SiGe) buffer layers epitaxially grown on the siliconsubstrate 10. The germanium concentration of the SiGe buffer layers mayincrease from 30 atomic % germanium for the bottom-most buffer layer to70 atomic % germanium for the top-most buffer layer.

As shown in FIGS. 1A-1C, the semiconductor wires 25, which are channellayers, are disposed over the substrate 10. In some embodiments, thesemiconductor wires 25 are disposed over a fin structure 11 (FIG. 5)protruding from the substrate 10. Each of the channel layers 25 iswrapped around by a gate dielectric layer 82 and a gate electrode layer84. The thickness of the semiconductor wires 25 is in a range from about5 nm to about 15 nm and the width of the semiconductor wires 25 is in arange from about 5 nm to about 15 nm in some embodiments. In someembodiments, the gate dielectric layer 82 includes an interfacial layerand a high-k dielectric layer. The gate structure includes the gatedielectric layer 82, the gate electrode layer 84 and sidewall spacers45. Although FIGS. 1A-1C show four semiconductor wires 25, the number ofthe semiconductor wires 25 is not limited to four, and may be as smallas one or more than four and may be up to ten. By adjusting the numbersof the semiconductor wires, a driving current of the GAA FET device canbe adjusted. In some embodiments, both n and p-type source/drain arewith or without wires 25.

Further, a source/drain epitaxial layer 50 is disposed over thesubstrate 10 as shown in FIGS. 1A and 1D. In some embodiments, thesource/drain epitaxial layer 50 is in direct contact with end faces ofthe channel layer 25, and is separated from the electrically conductinggate electrode layer 84 by insulating inner spacers 35 and the gatedielectric layer 82. In some embodiments, an additional insulating layer(not shown) is conformally formed on the inner surface of the spacerregions. As shown in FIG. 1A, the cross section along the X direction ofthe inner spacer 35 has a cross-sectional shape filling a recess in thesource/drain region and not in the channel region.

An interlayer dielectric (ILD) layer 70 is disposed over thesource/drain epitaxial layer 50 and a conductive contact layer 72 isdisposed on the source/drain epitaxial layer 50, and a conductive plug75 passing though the ILD layer 70 is disposed over the conductivecontact layer 72. The conductive contact layer 72 includes one or morelayers of conductive material. In some embodiments, the conductivecontact layer 72 includes a silicide layer, such as WSi, NiSi, TiSi orCoSi or other suitable silicide material or an alloy of a metal elementand silicon and/or germanium.

FIGS. 2A-2D show various views of a semiconductor FET device accordingto another embodiment of the present disclosure. FIG. 2A is a crosssectional view along the X direction (source-to-drain direction), FIG.2B is a cross sectional view along the Y1-Y1 direction of FIG. 2A, FIG.2C is a cross sectional view along the Y2-Y2 direction of FIG. 2A, andFIG. 2D shows a cross sectional view along the Y3-Y3 direction of FIG.2A. Material, configuration, dimensions and/or processes the same as orsimilar to the foregoing embodiments described with respect to FIGS.1A-1D may be employed in the embodiment of FIGS. 2A-2D, and detailedexplanation thereof may be omitted.

In this embodiment, the source/drain epitaxial layer 50 wraps aroundportions of the semiconductor wires 25 disposed at the source/drainregions, or the semiconductor wires 25 pass through the source/drainepitaxial layer 50.

In the embodiments of FIGS. 1A-1D and 2A-2D, the GAA FET is an n-typeGAA FET. The semiconductor wires 25 are made of Si or Si_(1-x)Ge_(x),where x is equal to or less than 0.2. The source/drain epitaxial layer50 is made of one or more of Si, Si:P (P doped Si), SiC or SiCP (P dopedSiC). In some embodiments, both n and p-type source/drain are with orwithout wires 25.

FIGS. 3A-3D show various views of a semiconductor FET device accordingto another embodiment of the present disclosure. FIG. 3A is a crosssectional view along the X direction (source-to-drain direction), FIG.3B is a cross sectional view along the Y1-Y1 direction of FIG. 3A, FIG.3C is a cross sectional view along the Y2-Y2 direction of FIG. 3A, andFIG. 3D shows a cross sectional view along the Y3-Y3 direction of FIG.3A. Material, configuration, dimensions and/or processes the same as orsimilar to the foregoing embodiments described with respect to FIGS.1A-2D may be employed in the embodiment of FIGS. 3A-3D, and detailedexplanation thereof may be omitted.

In the embodiments of FIGS. 3A-3D, the GAA FET shown in FIGS. 3A-3D is ap-type GAA FET. The semiconductor wires 20, which are channel layers andare made of Si_(1-x)Ge_(x), where x is equal to or more than about 0.2(hereinafter may be merely referred to as SiGe), are disposed over thesubstrate 10. In some embodiments, the semiconductor wires 20 aredisposed over a fin structure 11 (FIG. 5A) protruding from the substrate10. The thickness of the semiconductor wires 20 is in a range from about5 nm to about 15 nm and the width of the semiconductor wires 20 is in arange from about 5 nm to about 15 nm in some embodiments. Each of thechannel layers 20 is wrapped around by a gate dielectric layer 82 and agate electrode layer 84. In some embodiments, the gate dielectric layer82 includes an interfacial layer and a high-k dielectric layer. The gatestructure includes the gate dielectric layer 82, the gate electrodelayer 84 and sidewall spacers 45. Although FIGS. 3A-3C show foursemiconductor wires 20, the number of the semiconductor wires 20 is notlimited to four, and may be as small as one or more than four and may beup to ten.

A source/drain epitaxial layer 55 is disposed over the substrate 10, asshown in FIGS. 3A and 3D. The source/drain epitaxial layer 55 is indirect contact with end faces of the channel layers 20, and is separatedfrom the electrically conducting layer of gate electrode layer 84 byinsulating layers of insulating inner spacers 65 and the gate dielectriclayer 82. The source/drain epitaxial layer 55 is made of one or more ofSi, SiGe and SiGeB. In some embodiments, an additional insulating layer(not shown) is conformally formed on the inner surface of the spacerregions. In some embodiments, both n and p-type source/drain are with orwithout wires 20.

As shown in FIG. 3A, the inner spacer 65 has a cross sectional shapealong the X direction formed in a recess formed in the source/drainregion and not in the channel region. In some embodiments, the innerspacers 65 are disposed above the uppermost semiconductor wire 20 alongz direction.

FIGS. 4A-4D show various views of a p-type GAA FET device according toanother embodiment of the present disclosure. FIG. 4A is a crosssectional view along the X direction (source-to-drain direction), FIG.4B is a cross sectional view corresponding to Y1-Y1 of FIG. 4A, FIG. 4Cis a cross sectional view corresponding to Y2-Y2 of FIG. 4A and FIG. 4Dshows a cross sectional view corresponding to Y3-Y3 of FIG. 4A.Material, configuration, dimensions and/or processes the same as orsimilar to the foregoing embodiments described with respect to FIGS.1A-3D may be employed in the embodiment of FIGS. 4A-4D, and detailedexplanation thereof may be omitted.

In this embodiment, the source/drain epitaxial layer 55 wraps around endportions of the semiconductor wires 20 disposed at the source/drainregions, or the semiconductor wires 20 pass through the source/drainepitaxial layer 55. In some embodiments, both n and p-type source/drainare with or without wires 20.

In some embodiments, two or more of the GAA FETs shown in FIGS. 1A-4Dare disposed on one semiconductor substrate (chip) to achieve variouscircuit functions.

FIGS. 5A to 20B show various operations of manufacturing a semiconductorFET device according to an embodiment of the present disclosure. InFIGS. 7A-20B, the “A” figures (or left figures) are cross sectionalviews along the X direction (i.e. the source-to-drain direction) for ann-type GAA FET, and the “B” figures (or right figure) are crosssectional views along the X direction for a p-type GAA FET. It isunderstood that additional operations can be provided before, during,and after processes shown by FIGS. 5A-20B, and some of the operationsdescribed below can be replaced or eliminated, for additionalembodiments of the method. The order of the operations/processes may beinterchangeable. Material, configuration, dimensions and/or processesthe same as or similar to the foregoing embodiments described withrespect to FIGS. 1A-4D may be employed in the embodiment of FIGS.5A-20B, and detailed explanation thereof may be omitted.

As shown in FIGS. 5A and 5B, fin structures 29, in which firstsemiconductor layers 20 and second semiconductor layers 25 arealternately stacked on a bottom fin 11, are formed over the substrate10. The fin structures 29 protrude from an isolation insulating layer15. The fin structures 29 can be formed by the following operations.

Stacked semiconductor layers are formed over the substrate 10. Thestacked semiconductor layers include the first semiconductor layers 20and the second semiconductor layers 25. The first semiconductor layers20 and the second semiconductor layers 25 are made of materials havingdifferent lattice constants, and may include one or more layers of Si,Ge, SiGe, GaAs, InSb, GaP, GaSb, InAlAs, InGaAs, GaSbP, GaAsSb or InP.

In some embodiments, the first semiconductor layers 20 and the secondsemiconductor layers 25 are made of Si, a Si compound, SiGe, Ge or a Gecompound. In one embodiment, the first semiconductor layers 20 areSi_(1-x)Ge_(x), where x is equal to or more than about 0.2, or Ge(x=1.0) and the second semiconductor layers 25 are Si or Si_(1-y)Ge_(y),where y is equal to or less than about 0.2. In this disclosure, an “M”compound” or an “M based compound” means the majority of the compound isM.

The first semiconductor layers 20 and the second semiconductor layers 25are epitaxially formed over the substrate 10. The thickness of the firstsemiconductor layers 20 may be equal to or greater than that of thesecond semiconductor layers 25, and is in a range from about 2 nm toabout 20 nm in some embodiments, and is in a range from about 5 nm toabout 15 nm in other embodiments. The thickness of the secondsemiconductor layers 25 is in a range from about 2 nm to about 20 nm insome embodiments, and is in a range from about 5 nm to about 15 nm inother embodiments. The thickness of each of the first semiconductorlayers 20 may be the same, or may vary.

In some embodiments, the bottom first semiconductor layer (the closestlayer to the substrate 10) is thicker than the remaining firstsemiconductor layers. The thickness of the bottom first semiconductorlayer is in a range from about 10 nm to about 50 nm in some embodiments,or is in a range from 20 nm to 40 nm in other embodiments.

In some embodiments, the mask layer including a first mask layer and asecond mask layer is formed over the stacked layers. The first masklayer is a pad oxide layer made of a silicon oxide, which can be formedby a thermal oxidation. The second mask layer is made of a siliconnitride, which is formed by chemical vapor deposition (CVD), includinglow pressure CVD (LPCVD) and plasma enhanced CVD (PECVD), physical vapordeposition (PVD), atomic layer deposition (ALD), or other suitableprocess. The mask layer is patterned into a mask pattern by usingpatterning operations including photo-lithography and etching.

Next, the stacked layers of the first and second semiconductor layers20, 25 are patterned by using the patterned mask layer, thereby thestacked layers are formed into fin structures 29 extending in the Xdirection, as shown in FIGS. 5A and 5B. In FIG. 5B, two fin structures29 are arranged in the Y direction. But the number of the fin structuresis not limited to two, and may be as small as one or three or more. Insome embodiments, one or more dummy fin structures are formed on bothsides of the fin structures 29 to improve pattern fidelity in thepatterning operations. As shown in FIG. 5B the fin structures 29 haveupper portions constituted by the stacked semiconductor layers 20, 25and well portions 11.

The width of the upper portion of the fin structure 29 along the Ydirection is in a range from about 10 nm to about 40 nm in someembodiments, and is in a range from about 20 nm to about 30 nm in otherembodiments.

The stacked fin structure 29 may be patterned by any suitable method.For example, the structures may be patterned using one or morephotolithography processes, including double-patterning ormulti-patterning processes. Generally, double-patterning ormulti-patterning processes combine photolithography and self-alignedprocesses, allowing patterns to be created that have, for example,pitches smaller than what is otherwise obtainable using a single, directphotolithography process. For example, in one embodiment, a sacrificiallayer is formed over a substrate and patterned using a photolithographyprocess. Spacers are formed alongside the patterned sacrificial layerusing a self-aligned process. The sacrificial layer is then removed, andthe remaining spacers may then be used to pattern the stacked finstructure 29. By using this spacer patterning technique, a devicefeature smaller than the smallest value allowed in photolithographic andetching methods can be produced.

After the fin structures 29 are formed, an insulating material layer 15(also called “isolation insulating layer”) including one or more layersof insulating material is formed over the substrate so that the finstructures are fully embedded in the insulating layer. The insulatingmaterial for the insulating layer 15 may include silicon oxide, siliconnitride, silicon oxynitride (SiON), SiOCN, SiCN, fluorine-doped silicateglass (FSG), or a low-k dielectric material, formed by LPCVD (lowpressure chemical vapor deposition), plasma-CVD or flowable CVD. Ananneal operation may be performed after the formation of the insulatinglayer. Then, a planarization operation, such as a chemical mechanicalpolishing (CMP) method and/or an etch-back method, is performed suchthat the upper surface of the uppermost second semiconductor layer 25 isexposed from the insulating material layer. In some embodiments, one ofmore fin liner layers (not shown) are formed over the fin structuresbefore forming the insulating material layer. In some embodiments, thefin liner layers include a first fin liner layer formed over thesubstrate 10 and sidewalls of the bottom part of the fin structures 11,and a second fin liner layer formed on the first fin liner layer. Thefin liner layers are made of silicon nitride or a silicon nitride-basedmaterial (e.g., SiON, SiCN or SiOCN). The fin liner layers may bedeposited through one or more processes such as physical vapordeposition (PVD), chemical vapor deposition (CVD), or atomic layerdeposition (ALD), although any acceptable process may be utilized.

Then, as shown in FIG. 5B, the insulating material layer is recessed toform the isolation insulating layer 15 so that the upper portions of thefin structures 29 are exposed. With this operation, the fin structures29 are separated from each other by the isolation insulating layer 15,which is also called a shallow trench isolation (STI). In someembodiments, the isolation insulating layer 15 is formed through aprocess such as CVD, flowable CVD (FCVD), or a spin-on-glass process,although any acceptable process may be utilized.

In some embodiments, the insulating material layer 15 is recessed untilthe upper portion of the fin structure (well layer) 11 is exposed. Inother embodiments, the upper portion of the fin structure 11 is notexposed. The first semiconductor layers 20 are sacrificial layers whichare subsequently partially removed, and the second semiconductor layers25 are subsequently formed into semiconductor wires as channel layers ofan n-type GAA FET. For a p-type GAA FET, the second semiconductor layers25 are sacrificial layers which are subsequently partially removed, andthe first semiconductor layers 20 are subsequently formed intosemiconductor wires as channel layers.

After the isolation insulating layer 15 is formed, a sacrificial (dummy)gate structure 49 is formed over the exposed fin structures, as shown inFIGS. 6A and 6B. The sacrificial gate structure 49 is formed over aportion of the fin structures which is to be a channel region. Thesacrificial gate structure 49 defines the channel region of the GAA FET.The sacrificial gate structure 49 includes a sacrificial gate dielectriclayer 41 and a sacrificial gate electrode layer 42. The sacrificial gatedielectric layer 41 includes one or more layers of insulating material,such as a silicon oxide-based material. In one embodiment, silicon oxideformed by CVD is used. The thickness of the sacrificial gate dielectriclayer 41 is in a range from about 1 nm to about 5 nm in someembodiments.

The sacrificial gate structure 49 is formed by first blanket depositingthe sacrificial gate dielectric layer 41 over the fin structures. Asacrificial gate electrode layer is then blanket deposited on thesacrificial gate dielectric layer and over the fin structures, such thatthe fin structures are fully embedded in the sacrificial gate electrodelayer. The sacrificial gate electrode layer includes silicon such aspolycrystalline silicon or amorphous silicon. The thickness of thesacrificial gate electrode layer is in a range from about 100 nm toabout 200 nm in some embodiments. In some embodiments, the sacrificialgate electrode layer is subjected to a planarization operation. Thesacrificial gate dielectric layer and the sacrificial gate electrodelayer are deposited using CVD, including LPCVD and PECVD, PVD, ALD, orother suitable process. Subsequently, a mask layer is formed over thesacrificial gate electrode layer. The mask layer includes a pad siliconnitride layer 43 and a silicon oxide mask layer 44.

Next, a patterning operation is performed on the mask layer andsacrificial gate electrode layer is patterned into the sacrificial gatestructure 49, as shown in FIGS. 6A and 6B. The sacrificial gatestructure includes the sacrificial gate dielectric layer 41, thesacrificial gate electrode layer 42 (e.g. poly silicon), the pad siliconnitride layer 43 and the silicon oxide mask layer 44. By patterning thesacrificial gate structure, the stacked layers of the first and secondsemiconductor layers are partially exposed on opposite sides of thesacrificial gate structure, thereby defining source/drain (source/drain)regions, as shown in FIGS. 6A and 6B. In this disclosure, a source and adrain are interchangeably used and the structures thereof aresubstantially the same. In FIGS. 6A and 6B, one sacrificial gatestructure is formed over two fin structures, but the number of thesacrificial gate structures is not limited to one. Two or moresacrificial gate structures are arranged in the X direction in someembodiments. In certain embodiments, one or more dummy sacrificial gatestructures are formed on both sides of the sacrificial gate structuresto improve pattern fidelity.

Further, a first cover layer 45 for forming sidewall spacers is formedover the sacrificial gate structure 49, as shown in FIGS. 6A and 6B. Thefirst cover layer 45 is deposited in a conformal manner so that it isformed to have substantially equal thicknesses on vertical surfaces,such as the sidewalls, horizontal surfaces, and the top of thesacrificial gate structure, respectively. The first cover layer 45includes one or more of Si₃N₄, N₂OSi₂, SiCN, SiCO, SiOCN or any othersuitable dielectric material. The cover layer 45 can be formed by ALD orCVD, or any other suitable method.

FIG. 7A shows a cross sectional view along the X direction in an n-typeregion, and FIG. 7B shows a cross sectional view along the X directionin a p-type region. Next, the p-type region is covered by a protectivelayer 101, such a photo resist layer, as shown in FIG. 7B. In the n-typeregion (FIG. 7A), the first cover layer 45 is anisotropically etched toremove the first cover layer 45 disposed on the source/drain region,while leaving the first cover layer 45 as sidewall spacers on side facesof the sacrificial gate structure 49. Then the stacked structure of thefirst semiconductor layers 20 and the second semiconductor layer 25 isetched down at the source/drain region, by using one or more lithographyand etching operations, thereby forming a source/drain space 21. In someembodiments, the substrate 10 (or the bottom part of the fin structures11) is also partially etched.

Subsequently, as shown in FIG. 8A, a source/drain epitaxial layer 50 isformed in the source/drain space 21, in the n-type region. Thesource/drain epitaxial layer 50 includes one or more layers of Si, Si:P(P doped Si), SiC and SiC:P (P doped SiC) for an n-channel FET. Thesource/drain epitaxial layer 50 is formed by an epitaxial growth methodusing CVD, ALD or molecular beam epitaxy (MBE). As shown in FIGS. 8A and8B, the source/drain epitaxial layer 50 is selectively formed onsemiconductor regions. The source/drain epitaxial layer 50 is formed incontact with end faces of the second semiconductor layers 25. In FIG.8B, after the selective deposition of the source/drain epitaxial layer,the protective cover 101 covering the p-type region is removed.

Then, as shown in FIGS. 9A and 9B, a second cover layer 47 is formedboth in the n-type region and the p-type region. The second cover layer47 includes one of silicon nitride and silicon oxide (SiO₂), SiON, SiOC,SiCN and SiOCN, or any other suitable dielectric material. The secondcover layer 47 is made of a different material than the sidewall spacers(first cover layer) 45. The second cover layer 47 can be formed byatomic layer deposition (ALD) or any other suitable methods.

Next, as shown in FIGS. 10A and 10B, while the n-type region is coveredby a protective layer 111, for example, a photoresist pattern, thesecond cover layer 47 in the p-type region is removed. Further, thefirst cover layer 45 is anisotropically etched to remove the first coverlayer 45 disposed on the source/drain region so as to expose thesource/drain region, while leaving the first cover layer 45 as sidewallspacers on side faces of the sacrificial gate structure 49 in the p-typeregion.

Further, as shown in FIG. 11B, the second semiconductor layer 25 in thesource/drain region of the fin structure, which is not covered by thesacrificial gate structure, is etched, thereby leaving the firstsemiconductor layers 20 in the source/drain region. During the etchingin the p-type region in FIG. 11B, the n-type region in FIG. 11A iscovered by the protective layer 111 in some embodiments. In otherembodiments, the protective layer 111 in the n-type region in FIG. 11Ais removed before etching the source/drain region in the p-type region,and the second cover layer 47 protects the n-type region. In the p-typeregion, the second semiconductor layers 25 are laterally etched in the Xdirection within the source/drain space 51, thereby forming cavities 51,as shown in FIG. 11B. When the first semiconductor layers 20 are Ge orSiGe and the second semiconductor layers 25 are Si, the secondsemiconductor layers 25 can be selectively etched by using a wet etchantsuch as, but not limited to, an ammonium hydroxide (NH₄OH) solutionand/or a tetramethylammonium hydroxide (TMAH) solution along a selectedappropriate crystal orientation (such as <001>, <101>, or <110>, etc.)of the second semiconductor layers 25.

Subsequently, as shown in FIGS. 12A and 12B, a source/drain epitaxiallayer 55 is formed in the source/drain space 51 (FIG. 11B), in thep-type region. The source/drain epitaxial layer 55 includes one or morelayers of Si, SiGe and Ge for a p-channel FET. For the p-channel FET,boron (B) may also be contained in the source/drain. The source/drainepitaxial layer 55 is formed by an epitaxial growth method using CVD,ALD or molecular beam epitaxy (MBE). The source/drain epitaxial layer 55is formed to wrap around portions of the first semiconductor layers 20.In some embodiments, the first semiconductor layers 20 pass through thesource/drain epitaxial layer 55 (e.g. FIG. 16B). After the source/drainepitaxial layer 55 is selectively formed on semiconductor regions in thep-type region, the second cover layer 47 in the n-type region isremoved, as shown in FIG. 12A.

Subsequently, an interlayer dielectric (ILD) layer 70 is formed over thesource/drain epitaxial layers 50 and 55. The materials for the ILD layer70 include compounds comprising Si, O, C and/or H, such as siliconoxide, SiCOH and SiOC. Organic materials, such as polymers, may be usedfor the ILD layer 70. After the ILD layer 70 is formed, a planarizationoperation, such as CMP, is performed, so that the top portion of thesacrificial gate electrode layer 42 is exposed.

Then, the sacrificial gate electrode layer 42 and sacrificial gatedielectric layer 41 are removed. The ILD layer 70 protects thesource/drain epitaxial layers 50 and 55 during the removal of thesacrificial gate structures. The sacrificial gate structures can beremoved using plasma dry etching and/or wet etching. When thesacrificial gate electrode layer 42 is polysilicon and the ILD layer 70is silicon oxide, a wet etchant such as a TMAH solution can be used toselectively remove the sacrificial gate electrode layer 42. Thesacrificial gate dielectric layer 41 is thereafter removed using plasmadry etching and/or wet etching.

After the sacrificial gate structures are removed, a protective layer isformed to cover the p-type region, and the first semiconductor layers 20are removed in the n-type region, thereby forming wires (channelregions) of the second semiconductor layers 25, as shown in FIG. 13A.FIG. 13A shows that the first semiconductor layers 20 are partiallyremoved, and portions of the first semiconductor layers 20 contactingthe source/drain epitaxial layers remain. The remaining portions of thefirst semiconductor layers 20 between the second semiconductor layers 25have a cross-sectional recess shape. In some embodiments, the firstsemiconductor layers 20 are completely etched and the surface of thesource/drain epitaxial layers 50 contacting the first semiconductorlayers 20 is also etched to form recesses. The first semiconductorlayers 20 can be removed or etched using an etchant that can selectivelyetch the first semiconductor layers 20 against the second semiconductorlayers 25, as set forth above. In some embodiments, first semiconductorlayers 20 are etched using wet etching utilizes an HCl acid solution ora mixed solution of NH₄OH, H₂O₂ and H₂O. When the first semiconductorlayers 20 are Ge or SiGe and the second semiconductor layers 25 are Si,the first semiconductor layers 20 can be selectively etched by using awet etchant such as, but not limited to, an HCl solution. By using theHCl acid solution and by selecting an appropriate crystal orientation ofthe first semiconductor layers 20, the etched surface of the end facesof the first semiconductor layers 20 have a recess shape, defined by thefacets of the first semiconductor layers 20. After selective etching ofthe first semiconductor layers 20, the protective layer 101 in thep-type region is removed (now shown).

As shown in FIG. 13A, since there is no etch stopping layer formedadjacent to the source/drain epitaxial layer 50, etching does not stopat a vertical plane of the outer surface of the sidewall spacer 45, andportions of the first semiconductor layers 20 positioned underneath thesidewall spacers 45 are etched. Under each sidewall spacer 45, a portionof the first semiconductor layer 20 remains and has a recess having across-sectional shape along X-direction depending on the facets obtainedby selective etching the first semiconductor layers 20 to form therecess shape, for example, the recesses of the remaining firstsemiconductor layers 20, after etching, of the embodiment in FIG. 13Ahave a circular concave cross-sectional shape along X-direction. Otherpossible cross-sectional shapes along X direction include a triangularrecess having (1116) facet and a pentagonal recess having (100) and(110) facets. In some embodiments, although not shown in FIG. 13A, thefirst semiconductor layer 20 can be completely etched and thesource/drain epitaxial layer 50 is etched to have a recess having theabove described cross-sectional shapes. The channel formation operationsfor the n-type region are performed, while the p-type region is coveredby a protective layer.

Similarly, the second semiconductor layers 25 are removed in the p-typeregion, thereby forming wires (channel regions) of the firstsemiconductor layers 20, as shown in FIG. 13B. The second semiconductorlayers 25 can be removed or etched using an etchant that can selectivelyetch the second semiconductor layers 25 against the first semiconductorlayers 20, as set forth above. As shown in FIG. 13B, since there is noetch stopping layer formed adjacent to the source/drain epitaxial layer55, etching does not stop at a vertical plane of the outer surface ofthe sidewall spacer 45, and portions or entirety of the secondsemiconductor layers 25 positioned underneath the sidewall spacers 45are etched. In some embodiments, although not shown in FIG. 13B, undereach sidewall spacer 45, a portion of the second semiconductor layer 25remains and has a recess having a cross-sectional shape alongX-direction depending on the facets, for example, the recesses of theremaining second semiconductor layers 25, after etching, of theembodiment in FIG. 13B have a circular concave cross-sectional shapealong X-direction. Other possible cross-sectional shapes along Xdirection include a triangular recess having (111) facet and apentagonal recess having (100) and (110) facets. As shown in FIG. 13B,the second semiconductor layer 25 is completely etched and a portion ofthe each of the source/drain epitaxial layer 55 is etched to have arecess having any of the above described cross-sectional shapes. Thechannel formation operations for the p-type region are performed, whilethe n-type region is covered by a protective layer. The formation of thechannel regions for the p-type region can be performed after theformation of the channel regions for the n-type region.

In FIGS. 14A and 14B, a first insulating layer 30 is conformally formedon the etched lateral ends of the first semiconductor layers 20 and onend faces of the second semiconductor layers 25 in the source/drainspace 21 and over the sacrificial gate structure. The first insulatinglayer 30 includes one of silicon nitride and silicon oxide (SiO₂), SiON,SiOC, SiCN and SiOCN, or any other suitable dielectric material. Thefirst insulating layer 30 is made of a different material than thesidewall spacers (first cover layer) 45. The first insulating layer 30has a thickness in a range from about 1.0 nm to about 10.0 nm. In otherembodiments, the first insulating layer 30 has a thickness in a rangefrom about 2.0 nm to about 5.0 nm. The first insulating layer 30 can beformed by ALD or any other suitable methods. In some embodiments, thefirst cover layer 30 fully fills the spaces around the semiconductorwires 20 and 25 as shown in FIGS. 15A and 15B, and in other embodiments,the first cover layer 30 only partially fills the spaces around thesemiconductor wires 20 and 25.

After the first insulating layer 30 is formed, an etching operation isperformed to partially remove the first insulating layer 30, therebyforming inner spacers 35 for the n-type region as shown in FIG. 15A andinner spacers 65 for the p-type region as shown in FIG. 15B. That is,anisotropic etching is performed to remove all the materials of thefirst insulating layer 30 except the materials of the first insulatinglayer 30 in the recess. In this embodiment shown in FIGS. 14A and 14B, aprotective layer is not used, and in such a case, the first insulatinglayer 30 in the p-type region is simultaneously removed during theetching operation performed in the n-type region. In some embodiments,the p-type region is covered by a protective layer while the n-typeregion is undergoing etching. In some embodiments, before forming thefirst insulating layer 30, an additional insulating layer having asmaller thickness than the first insulating layer 30 is formed, and thusthe inner spacers 35 have a two-layer structure. The first insulatinglayer 30 is formed to fill the recesses formed in the remaining firstsemiconductor layer 20 or the recesses formed in the source/drainepitaxial layer 50 when the first semiconductor layer 20 is completelyremoved, and after etching, becomes inner spacers 35 or 65. Also,because the recesses are formed in the remaining first semiconductorlayer 20 below the sidewall spacer 45 or in the source/drain epitaxiallayer 50, the inner spacers 35 or 65 are formed in a region notincluding the gate electrode 84, in some embodiments. That is, in someembodiments, the inner spacers 35 or 65 are formed in a region below thesidewall spacer 45. In some embodiments, the inner spacers 35 or 65 areformed in source/drain region. Because of the shape of the recess inwhich the inner spacers 35 or 65 are formed, the inner spacer 35 or 65has a cross-sectional shape convex toward the adjacent source/drainregion, in some embodiments. The surface of the inner spacer 35 or 65opposite to the convex shape may have a recess surface (FIGS. 17A, 17D,and 17E) or a flat surface (FIGS. 17B and 17C) contacting the gatedielectric layer 82, in some embodiments. After selective etch, therecess opens toward the gate electrode layer 84 and positioned in thegap between two wires (an upper wire and a lower wire with respect tothe gap).

In FIGS. 16A and 16B, after the inner spacers 35 for the n-type regionand the inner spacers 65 for the p-type region are formed, a gatedielectric layer 82 is formed around each channel layer for the n-typeregion and the p-type region. A gate electrode layer 84 is subsequentlyformed on the gate dielectric layer 82, as shown in FIGS. 16A and 16B.In some embodiments, the structure and/or material of the gate electrodefor the n-type GAA FET are different from the structure and/or materialof the gate electrode for the p-type GAA FET.

In certain embodiments, the gate dielectric layer 82 includes one ormore layers of a dielectric material, such as silicon oxide, siliconnitride, or high-k dielectric material, other suitable dielectricmaterial, and/or combinations thereof. Examples of high-k dielectricmaterial include HfO₂, HfSiO, HfSiON, HfTaO, HfTiO, HfZrO, zirconiumoxide, aluminum oxide, titanium oxide, hafnium dioxide-alumina(HfO₂—Al₂O₃) alloy, other suitable high-k dielectric materials, and/orcombinations thereof. In some embodiments, the gate dielectric layer 82includes an interfacial layer (not shown) formed between the channellayers and the dielectric material.

The gate dielectric layer 82 may be formed by CVD, ALD or any suitablemethod. In one embodiment, the gate dielectric layer 82 is formed usinga highly conformal deposition process such as ALD in order to ensure theformation of a gate dielectric layer having a uniform thickness aroundeach channel layer. The thickness of the gate dielectric layer 82 is ina range from about 1 nm to about 6 nm in one embodiment.

The gate electrode layer 84 is formed on the gate dielectric layer 82 tosurround each channel layer. The gate electrode 84 includes one or morelayers of conductive material, such as polysilicon, aluminum, copper,titanium, tantalum, tungsten, cobalt, molybdenum, tantalum nitride,nickel silicide, cobalt silicide, TiN, WN, TiAl, TiAlN, TaCN, TaC,TaSiN, metal alloys, other suitable materials, and/or combinationsthereof.

The gate electrode layer 84 may be formed by CVD, ALD, electro-plating,or other suitable method. The gate electrode layer is also depositedover the upper surface of the ILD layer 70. The gate dielectric layerand the gate electrode layer formed over the ILD layer 70 are thenplanarized by using, for example, CMP, until the top surface of the ILDlayer 70 is revealed. In some embodiments, after the planarizationoperation, the gate electrode layer 84 is recessed and a cap insulatinglayer (not shown) is formed over the recessed gate electrode 84. The capinsulating layer includes one or more layers of a silicon nitride-basedmaterial, such as silicon nitride. The cap insulating layer can beformed by depositing an insulating material followed by a planarizationoperation.

In certain embodiments of the present disclosure, one or more workfunction adjustment layers (not shown) are interposed between the gatedielectric layer 82 and the gate electrode 84. The work functionadjustment layers are made of a conductive material such as a singlelayer of TiN, TaN, TaAlC, TiC, TaC, Co, Al, TiAl, HfTi, TiSi, TaSi orTiAlC, or a multilayer of two or more of these materials. For then-channel FET, one or more of TaN, TaAlC, TiN, TiC, Co, TiAl, HfTi, TiSiand TaSi is used as the work function adjustment layer, and for thep-channel FET, one or more of TiAlC, Al, TiAl, TaN, TaAlC, TiN, TiC andCo is used as the work function adjustment layer. The work functionadjustment layer may be formed by ALD, PVD, CVD, e-beam evaporation, orother suitable process. Further, the work function adjustment layer maybe formed separately for the n-channel FET and the p-channel FET whichmay use different metal layers.

Subsequently, contact holes are formed in the ILD layer 70 by using dryetching, thereby exposing the upper portion of the source/drainepitaxial layer 50. In some embodiments, a silicide layer is formed overthe source/drain epitaxial layer 50. The silicide layer includes one ormore of WSi, CoSi, NiSi, TiSi, MoSi and TaSi. Then, a conductive contactlayer 72 is formed in the contact holes as shown in FIGS. 1A-1D. Theconductive contact layer 72 includes one or more of Co, Ni, W, Ti, Ta,Cu, Al, TiN and TaN. Further, a conductive contact plug 75 is formed onthe conductive contact layer 72. The conductive contact plug 75 includesone or more layers of Co, Ni, W, Ti, Ta, Cu, Al, TiN and TaN.

It is understood that the GAA FETs undergo further CMOS processes toform various features such as contacts/vias, interconnect metal layers,dielectric layers, passivation layers, etc.

FIGS. 17A, 17B, 17C, 17D, and 17E show various embodiments of innerspacers 35 or 65 coated with gate dielectric layer 82. As shown in FIGS.17A, 17B, 17C, 17D, and 17E, the portions of the inner spacers 35 or 65not coated by the gate dielectric layer 82 are formed in recessesprovided in a region not overlapping the gate electrode layer 84. Theformation of the surface of the portion of the inner spacers 35 or 65depends on the facets provided in the source/drain region byappropriately selecting the principal surface orientation of thesemiconductor substrate 10 and/or types of etching solutions used toremove the first and/or second semiconductor layers. FIGS. 17B and 17Dshow (111) facets of the inner spacers 35 or 65 while FIGS. 17C and 17Eshow (100) and (110) facets of the inner spacers 35 or 65. Byengineering the facets provided in the source/drain region by, forexample, appropriately selecting the principal surface orientation ofthe semiconductor substrate 10 and/or types of etching solutions used toremove the first and/or second semiconductor layers, the shape of theinner spacers 35 or 65 can be designed for specific purposes, in someembodiments. In FIGS. 17A, 17B, 17C, 17D, and 17E, the inner spacers 35or 65 have cross-sectional shape convex toward the adjacent source/drainregion and the surface opposite to the convex shape may have a recessshape (FIGS. 17A, 17D, and 17E) or a flat shape (FIGS. 17B and 17C), insome embodiments.

The various embodiments or examples described herein offer severaladvantages over the existing art. For example, in the presentdisclosure, in a GAA FET, an inner spacer has a cross-sectional shapeformed in a recess provided in the source/drain region. The inner spacerin this disclosure does not require extra space as it is formed in therecess provided in the source/drain region. Also, the inner spacersreinforce the structure of the n-type or p-type region and provideultimate electrical property for the device. The methods disclosedherein uniformly form the inner spacers by using wet etching. With theforegoing embodiments, it is possible to more precisely control thethickness, the shape and/or the location of the inner spacers and thusto control capacitances around the source/drain and the gate.

It will be understood that not all advantages have been necessarilydiscussed herein, no particular advantage is required for allembodiments or examples, and other embodiments or examples may offerdifferent advantages.

In accordance with an aspect of the present disclosure, in a method ofmanufacturing a semiconductor device, a fin structure, in which firstsemiconductor layers and second semiconductor layers are alternatelystacked, is formed. A sacrificial gate structure is formed over the finstructure. A source/drain region of the fin structure, which is notcovered by the sacrificial gate structure, is etched, thereby forming asource/drain space. A source/drain epitaxial layer is formed in thesource/drain space. After the source/drain epitaxial layer is formed,the sacrificial gate structure is removed, thereby exposing a part ofthe fin structure. The first semiconductor layers are removed from theexposed fin structure, thereby forming channel layers including thesecond semiconductor layers. Recesses are formed toward the source/drainepitaxial layer where the first semiconductor layers were removed. Innerspacers are formed in the recesses. A gate dielectric layer is formed tocover the inner spacers and a gate electrode layer is formed around thesecond semiconductor layer. The gate electrode layer is isolated fromthe source/drain epitaxial layer by the inner spacer and the gatedielectric layer. In one or more of the foregoing or followingembodiments, the recesses are formed in a region not overlapping thegate electrode layer. In one or more of the foregoing or followingembodiments, the recesses are formed in the source/drain region. In oneor more of the foregoing or following embodiments, the removing thefirst semiconductor layers is carried out by wet etching. In one or moreof the foregoing or following embodiments, the wet etching utilizes anHCl acid solution or a mixed solution of NH₄OH, H₂O₂ and H₂O. In one ormore of the foregoing or following embodiments, the inner spacer isformed by forming a dielectric layer in the recesses, and etching thedielectric layer. In one or more of the foregoing or followingembodiments, the etched dielectric layer has a concave or flat outersurface. In one or more of the foregoing or following embodiments, theinner spacers include at least one of silicon nitride and silicon oxide.In one or more of the foregoing or following embodiments, the innerspacers include at least one of SiOC, SiOCN and SiCN. In one or more ofthe foregoing or following embodiments, the gate dielectric layercontacting the inner spacer has a concave or flat shape. In one or moreof the foregoing or following embodiments, in the operation of removingthe first semiconductor layers, the first semiconductor layers in theexposed fin structure are selectively etched, thereby leaving the secondsemiconductor layers remaining. In one or more of the foregoing orfollowing embodiments, the second semiconductor layer is a nanowirelayer. In one or more of the foregoing or following embodiments, therecesses are formed in remaining portions of the first semiconductorlayers contacting the source/drain epitaxial layer.

In accordance with an aspect of the present disclosure, a semiconductordevice includes semiconductor wires disposed over a substrate, asource/drain epitaxial layer in contact with the semiconductor wires, agate dielectric layer disposed on and wrapping around each channelregion of the semiconductor wires, a gate electrode layer disposed onthe gate dielectric layer and wrapping around the each channel region,and dielectric spacers disposed in recesses formed toward thesource/drain epitaxial layer. In one or more of the foregoing orfollowing embodiments, the dielectric spacers include at least one ofsilicon nitride and silicon oxide. In one or more of the foregoing orfollowing embodiments, the semiconductor wires are made of Si. In one ormore of the foregoing or following embodiments, the semiconductor wiresare made of SiGe. In one or more of the foregoing or followingembodiments, the dielectric spacers are in contact with the source/drainepitaxial layer. In one or more of the foregoing or followingembodiments, the dielectric spacers are spaced apart from thesource/drain epitaxial layer.

In accordance with another aspect of the present disclosure, asemiconductor device includes semiconductor wires disposed over asubstrate, a source/drain epitaxial layer in contact with thesemiconductor wires, a gate dielectric layer disposed on and wrappingaround each channel region of the semiconductor wires, a gate electrodelayer disposed on the gate dielectric layer and wrapping around the eachchannel region, and dielectric spacers having a concave or flat outersurface disposed in recesses formed toward the source/drain epitaxiallayer.

The foregoing outlines features of several embodiments or examples sothat those skilled in the art may better understand the aspects of thepresent disclosure. Those skilled in the art should appreciate that theymay readily use the present disclosure as a basis for designing ormodifying other processes and structures for carrying out the samepurposes and/or achieving the same advantages of the embodiments orexamples introduced herein. Those skilled in the art should also realizethat such equivalent constructions do not depart from the spirit andscope of the present disclosure, and that they may make various changes,substitutions, and alterations herein without departing from the spiritand scope of the present disclosure.

What is claimed is:
 1. A semiconductor device, comprising: semiconductorwires disposed over a channel region on a substrate; a source/drainepitaxial layer in contact with the semiconductor wires which do notpass through the source/drain epitaxial layer; a gate structure in thechannel region, the gate structure comprising: a gate dielectric layerdisposed on and wrapping around the semiconductor wires in the channelregion; and a gate electrode layer disposed on the gate dielectric layerand wrapping around the semiconductor wires in the channel region; anddielectric spacers disposed in recesses formed between the source/drainepitaxial layer and the gate structure at both ends of the channelregion, wherein each of the dielectric spacers has a curved face, whichis a convex shape convex toward the source/drain epitaxial layer.
 2. Thesemiconductor device of claim 1, wherein the curved face convex towardthe source/drain epitaxial layer is in contact with the gate dielectriclayer.
 3. The semiconductor device of claim 1, wherein each of thedielectric spacers has curved faces, one of which is the convex shapeconvex toward the source/drain epitaxial layer and the other one ofwhich is a concave shape concave toward the gate electrode in a crosssection.
 4. The semiconductor device of claim 1 wherein: the gatestructure further includes gate sidewall spacers, and the dielectricspacers are made of different material than the gate sidewall spacersand include at least one of SiOC, SiOCN and SiCN.
 5. The semiconductordevice of claim 1, wherein an interface between each of the dielectricspacers and the gate dielectric layer has a tapered shape having asmaller width toward the source/drain epitaxial layer.
 6. Thesemiconductor device of claim 1, wherein each of the dielectric spacersincludes two layers.
 7. The semiconductor device of claim 6, wherein oneof the two layers closer to the gate dielectric layer has a smallerthickness than the other one of the two layers.
 8. A semiconductordevice, comprising: semiconductor wires made of Si and disposed over achannel region on a substrate; a source/drain epitaxial layer in contactwith the semiconductor wires which pass through the source/drainepitaxial layer, wherein the source/drain epitaxial layer includes SiPand wraps around the semiconductor wires; a gate structure in thechannel region, the gate structure comprising: a gate dielectric layerdisposed on and wrapping around the semiconductor wires in the channelregion; and a gate electrode layer disposed on the gate dielectric layerand wrapping around the semiconductor wires in the channel region; andinner spacers disposed in recesses formed between the source/drainepitaxial layer and the gate structure at both ends of the channelregion.
 9. The semiconductor device of claim 8, wherein: each of thedielectric spacers has a curved face, and the curved face is convextoward the source/drain epitaxial layer.
 10. The semiconductor device ofclaim 8, wherein each of the dielectric spacers has curved faces, one ofwhich is the convex shape convex toward the source/drain epitaxial layerand the other one of which is a concave shape concave toward the gateelectrode in a cross section.
 11. The semiconductor device of claim 8,wherein: the gate structure further includes gate sidewall spacers, andthe dielectric spacers are made of different material than the gatesidewall spacers and include at least one of SiOC, SiOCN and SiCN. 12.The semiconductor device of claim 8, wherein an interface between eachof the dielectric spacers and the gate dielectric layer has a taperedshape having a smaller width toward the source/drain epitaxial layer.13. The semiconductor device of claim 8, wherein each of the dielectricspacers includes two layers.
 14. The semiconductor device of claim 13,wherein one of the two layers closer to the gate dielectric layer has asmaller thickness than the other one of the two layers.
 15. Asemiconductor device, comprising: semiconductor wires disposed over achannel region on a substrate; a source/drain epitaxial layer in contactwith the semiconductor wires which do not pass through the source/drainepitaxial layer; a gate structure in the channel region, the gatestructure comprising: a gate dielectric layer disposed on and wrappingaround the semiconductor wires in the channel region; a gate electrodelayer disposed on the gate dielectric layer and wrapping around thesemiconductor wires in the channel region; and gate sidewall spacersdisposed on opposing side faces of a part of the gate electrode layerabove an uppermost one of the semiconductor wires; and dielectricspacers disposed in recesses formed between the source/drain epitaxiallayer and the gate structure, wherein at least one of the dielectricspacers is located above the uppermost one of the semiconductor wiresand below the gate sidewall spacers.
 16. The semiconductor device ofclaim 15, wherein: each of the dielectric spacers has a curved face, andthe curved face is convex toward the source/drain epitaxial layer. 17.The semiconductor device of claim 15, wherein each of the dielectricspacers has curved faces, one of which is a convex shape convex towardthe source/drain epitaxial layer and the other one of which is a concaveshape concave toward the gate electrode in a cross section.
 18. Thesemiconductor device of claim 15, wherein: the dielectric spacers aremade of different material than the gate sidewall spacers and include atleast one of SiOC, SiOCN and SiCN.
 19. The semiconductor device of claim15, wherein an interface between each of the dielectric spacers and thegate dielectric layer has a tapered shape having a smaller width towardthe source/drain epitaxial layer.
 20. The semiconductor device of claim15, wherein each of the dielectric spacers includes two layers.